SEARCH · Engineering Papers

Results for “continuous integration”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 937 records · Page 52

All sources NASA NTRS DOE OSTI

DOE OSTI2023

Integrated Process Optimization for Biochemical Conversion

This research is motivated by the challenges faced during biomass processing in bioenergy plants. It has been observed that variations in biomass characteristics, such as moisture, ash, and carbohydrate contents cause variations in feeding of the system which led to underutilization of equipment and the reactor. The objective of this research is to ensure a continuous flow of biomass to the reactor in plants that use the biochemical conversion process to generate liquid fuels. The overall goal is to lower the cost of producing biofuels, which could lead to improving US’s energy independency and growing US’s rural economy. The research team developed analytical models, such as discrete element method (DEM) models and mathematical models. The DEM models are unit-level models that explicitly capture biomass characteristics and quantify the impacts of biomass characteristics on bulk material properties and the performance of specific equipment. The mathematical models are system-level models that capture the impacts of system infeed rate, equipment processing rate, storage location and capacity, and biomass characteristics on system throughput. The functional relations predicting the bulk material properties from DEM models are incorporated to the mathematical models. The models developed were validated and evaluated using data collected at Idaho National Laboratory’s biomass processing facility. Via these models, we identified process control strategies that ensure a continuous flow of biomass to the reactor, while meeting the requirements of biochemical conversion process. Our analysis indicates that sequencing of biomass bales based on moisture level, and carbohydrate contents could have a positive impact on reducing processing time and inventory level and increasing throughput rate. Short bale sequences that repeat frequently, seem to have the greatest impact on improving system’s performance. Based on our experiments, the total annual system operating costs reduced by 20-30%, and the maximum inventory level reduced by 3 to 4 times. The operating costs include the annual equipment amortization cost and processing cost. The implementation of the models developed requires the use of standardized bale format, Radio Frequency Identification technology, sensing and real time monitoring of material attributes, automated material handling equipment, and automated process control. The scope of the model proposed can be extended to include the whole supply chain. The supply chain models help identify how many bales of different biomass feedstock to purchase given biomass availability in the region, biomass price and quality, and the biomass processing capabilities of the biorefinery. Thus, the outcomes of supply chain models can be used to inform the design of long-term contracts among farmers and the biorefinery.

09 BIOMASS FUELS↗

DOE OSTI2023

Mechanical ventilation and indoor air quality in recently constructed U.S. homes in marine and cold-dry climates

Data were collected to characterize whole-house mechanical ventilation (WHMV) and indoor air quality (IAQ) in 55 homes in the Marine climate of Oregon and the Cold-Dry climate of Colorado in the U.S. Sixteen homes were monitored for two weeks, with and without WHMV operating. Ventilation airflows; airtightness; time-resolved CO 2 , PM2.5 and radon; and time-integrated NO 2 , NO X and formaldehyde were measured. Participants provided information about IAQ-impacting activities, perceptions and ventilation use. All homes had operational cooktop ventilation and bathroom exhaust. Thirty homes had equipment that could meet the ASHRAE 62.2–2010 standard with continuous or controlled runtime and 34 had some WHMV operating as found. Thirty-five of 46 participants with WHMV reported they did not know how to operate it, and only half of the systems were properly labeled. Two-week homes had lower formaldehyde, radon, CO 2 and NO (NO X -NO 2 ) when operated with WHMV, and had faster PM 2.5 decays following indoor emission events. Overall IAQ satisfaction was similar in Oregon and Colorado, but more Colorado participants (19% vs 3%) felt their IAQ could be improved and more reported dryness as a problem (58% vs. 14%). The collected data indicate that there are benefits of operating WHMV, even when continuous use may not be needed because outdoor pollutant concentrations are low and indoor sources do not present substantial challenges.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Long lifetime of bialkali photocathodes operating in high gradient superconducting radio frequency gun

Abstract High brightness, high charge electron beams are critical for a number of advanced accelerator applications. The initial emittance of the electron beam, which is determined by the mean transverse energy (MTE) and laser spot size, is one of the most important parameters determining the beam quality. The bialkali photocathodes illuminated by a visible laser have the advantages of high quantum efficiency (QE) and low MTE. Furthermore, Superconducting Radio Frequency (SRF) guns can operate in the continuous wave (CW) mode at high accelerating gradients, e.g. with significant reduction of the laser spot size at the photocathode. Combining the bialkali photocathode with the SRF gun enables generation of high charge, high brightness, and possibly high average current electron beams. However, integrating the high QE semiconductor photocathode into the SRF guns has been challenging. In this article, we report on the development of bialkali photocathodes for successful operation in the SRF gun with months-long lifetime while delivering CW beams with nano-coulomb charge per bunch. This achievement opens a new era for high charge, high brightness CW electron beams.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Leverage modern artificial intelligence (AI) enabled systems for waste reduction

Manufacturing industries continue to face challenges in reducing waste, as upstream strategies such as source reduction and product redesign require a deeper understanding of processes compared to conventional recycling methods. Recent advancements in artificial intelligence (AI) and machine learning (ML) have opened new opportunities to integrate modern computational techniques with traditional waste minimization strategies. This paper explores AI-enabled approaches for product redesign, source reduction, and recycling that can significantly reduce waste generation while improving efficiency and sustainability. AI-driven material substitution and lightweighting in product design enable discovery of novel materials with optimized properties, reducing waste without compromising performance. Reinforcement learning models optimize process parameters, raw material specifications, and machine sequencing to minimize production losses, while Industrial Internet of Things (IIoT) systems paired with AI analytics enhance real-time waste tracking, predictive maintenance, and quality inspection. Furthermore, AI-based demand forecasting and production planning reduce overproduction and excess inventory, as demonstrated in industrial applications. In recycling, ML-powered pattern recognition and robotic sorting technologies achieve higher accuracy in waste segregation, directly improving recycling efficiency. Complementary solutions such as smart bins and AI-enabled waste pickup scheduling optimize collection logistics, reducing both costs and emissions. Although implementation requires upfront investment in infrastructure and training, the long-term benefits include higher material efficiency, reduced waste, improved product quality, and stronger sustainability outcomes across the supply chain. By leveraging AI-enabled systems, manufacturers can align waste minimization efforts with circular economy principles, creating scalable solutions for both industry and society.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Investigating Vegetation Responses to Underground Nuclear Explosions Through Integrated Analyses

Vegetation has the potential to respond to underground nuclear explosions, yet these links have not been fully explored. Given the lack of previously described signatures, the changes in vegetation are possibly subtle. The integration of multiple different data streams is potentially a useful approach to improve signal detection. Here, we investigate whether semi-arid vegetation growth patterns responded to eight legacy underground nuclear tests at the Nevada National Security Site in southern Nevada, USA. We tested for spatial and temporal changes in vegetation cover, tree growth patterns, and tree leaf spectral properties using ground-based measurements, including those from tree-rings and hyperspectral surface vegetation reflectance, as well as space-based measurements of Normalized Difference Vegetation Index (NDVI) from Landsat. Multiple data streams suggest a localized (<1.2 km) spatial pattern whereby tree growth is enhanced closer to the source of the underground test relative to sites further away. We also observed a more regional (>1.2–9 km) pattern whereby tree growth is suppressed coincident with a drought beginning 1 year before the 1989 tests, but continuing in the 5 years following the tests, which is anomalous relative to what is expected based on the response of tree growth to previous droughts. furthermore, quantification of the relative effects of the tests on vegetation remains a challenge due to the coincident drought and the potential for other disturbances to have impacted tree growth at this time, but the integration of these data reveals a more nuanced growth response than any other one data set indicates alone.

63 RADIATION, THERMAL, AND OTHER ENVIRON. POLLUTAN↗

DOE OSTI2024

Phase field-volumetric lattice Boltzmann model of ion uptake in porous nuclear waste form materials under continuous flow

The flow field within the mesopores of sorbent particles plays a crucial role in radionuclide diffusion and ion uptake kinetics, thus, impacting the overall performance of porous nuclear waste form materials. To fundamentally understand the influence of microstructures and material properties on the radionuclide absorption and retention processes requires a coupled multi-physics model that considers the advection and diffusion within the flow field, the reaction at liquid-solid interfaces, and finally, the solid-state diffusion within a complex nanoporous medium. Here, this study employs the volumetric lattice Boltzmann method (VLBM) to accurately and efficiently calculate the steady state velocity field inside the mesopores of sorbent particles. The obtained velocity field is then utilized to calculate the advection of ions in the steady flow. A phase field (PF) model of ion uptake is used to describe the reaction occurring at the solid-liquid interface and diffusion inside the porous medium. The integrated PF-VLBM model is verified in terms of the mass conservation and numerical efficiency and validated qualitatively with experimental observation data. Then, it is applied to study the influence of thermodynamic and kinetic properties, as well as flow field conditions on the ion uptake kinetics. The numerical results demonstrate that the ion uptake kinetics in porous particles has three distinct stages, which is in agreement with the observations in continuous flow experiments. In the first stage, the kinetics is predominantly controlled by the flow field and ion diffusivity in the liquid phase. The kinetics in the second stage is primarily governed by ion diffusivity in the solid phase. In the third stage the system reaches a dynamic equilibrium with a net zero uptake flux at the interface. It is also found that porous structures significantly affect the efficiency and capacity of ion uptake. The simulation results can help to understand the physics behind the observed ion uptake kinetics in experiments and to facilitate the development of constitutive equations that can account for heterogeneous microstructures in engineering performance codes.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

RAMSeS: Rapid Analysis of Mission Software Systems

Over the past few decades, software has become ubiquitous as it has been integrated into nearly every aspect of society, including household appliances, consumer electronics, industrial control systems, public utilities, government operations, and military systems. Consequently, many critical national security questions can no longer be answered convincingly without understanding software, including its purpose, its capabilities, its flaws, its communication, or how it processes and stores data. As software continues to become larger, more complex, and more widespread, our ability to answer important mission questions and reason about software in a timely way is falling behind. Today, to achieve such understanding of third-party software, we rely predominantly on the ability of reverse engineering experts to manually answer each particular mission question for every software system of interest. This approach often requires heroic human effort that nevertheless fails to meet current mission needs and will never scale to meet future needs. The result is an emerging crisis: a massive and expanding gap between the national security need to answer mission questions about software and our ability to do so. Sandia National Laboratories has established the Rapid Analysis of Mission Software Systems (RAMSeS) effort, a collaborative long-term effort aimed at dramatically improving our nation’s ability to answer mission questions about third-party software by growing an ecosystem of tools that augment the human reverse engineer through automation, interoperability, and reuse. Focusing on static analysis of binary programs, we are attempting to identify reusable software analysis components that advance our ability to reason about software, to automate useful aspects of the software analysis process, and to integrate new methodologies and capabilities into a working ecosystem of tools and experts. We aim to integrate existing tools where possible, adapt tools when modest modifications will enable them to interoperate, and implement missing capability when necessary. Although we do hope to automate a growing set of analysis tasks, we will approach this goal incrementally by assisting the human in an ever-widening range of tasks.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

Impedance Methods for Analyzing Stability Impacts of Inverter-Based Resources: Stability Analysis Tools for Modern Power Systems

Power systems around the world are undergoing a major transformation because of the increasing shares of renewable energy, growing deployment of energy storage systems, proliferation of distributed energy resources, electrification of other sectors, and so on. In the United States, wind and solar provided almost 10% of electricity in 2019. The U.S. Energy Information Administration, in its 2020 Annual Energy Outlook, forecasted that the share of electricity from renewables will reach 38% by 2050, of which more than 80% will come from wind and solar. Wind and solar, along with battery energy storage systems, interface with the grid using power electronic inverters; hence, they are collectively referred to as inverter-based resources (IBRs). The increasing annual share of electricity from IBRs in a power system means that during more times of the year, the system will operate at a much higher concentration of IBRs. Figure 1 presents the hourly share of wind and solar generation in the Electric Reliability Council of Texas (ERCOT) system in Texas in 2019. While the annual wind share was at 20%, the instantaneous percentage share was much higher. Moments of high shares of IBRs (>50%) will continue to grow as more IBRs will be deployed in a power system.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Raman Spectroscopic In Situ Monitoring of Highly Turbid Media

The ability to run chemical processing more efficiently and cost effectively is a need that spans critical materials recovery and legacy nuclear waste cleanup. Sensors integrated to provide online monitoring are essential to addressing this need by providing near-real time feedback on process conditions, which can improve efficiency, aid in decision making, and reduce the need for grab sample measurements. Optical spectroscopy is well-suited for providing online chemical composition information and has been widely applied in varied chemical systems. However, applications in turbid matrices continue to represent substantial challenges to sensor performance, where absorption or scattering of excitation light can cause significant signal interference. Here, in this study, close-focus Raman probes are investigated for use in turbid media as a way to overcome the signal loss from the scattering of the Raman excitation source. This, paired with advanced data science techniques, allowed for the development of chemometric models for the accurate quantification of several analytes of interest (NO 3 – , NO 2 – , and PO 4 3– ) in highly turbid solutions with solids loadings of up to 20 wt %. This work focuses on offline sample measurement and characterization as an initial step toward the development of online monitoring capabilities. Chemical systems of interest were focused on nuclear waste at the Hanford Site, which represents highly complex matrices that could realize significant processing benefits through the integration of online monitoring.

Felmy, Heather M. [Pacific Northwest National Labo↗

DOE OSTI2020

Water-Fed Hydroxide Exchange Membrane Electrolyzer Enabled by a Fluoride-Incorporated Nickel–Iron Oxyhydroxide Oxygen Evolution Electrode

Here, we have developed a dissolved oxygen and galvanic corrosion method to synthesize vertically aligned fluoride-incorporated nickel–iron oxyhydroxide nanosheet arrays on a compressed Ni foam as an efficient self-supported oxygen evolution electrode. It is integrated with poly(aryl piperidinium) hydroxide exchange membrane and ionomers with high ion exchange capacity into a hydroxide exchange membrane electrolyzer fed with pure water, which achieves a performance of 1020 mA cm –2 at 1.8 V and prevents the detachment of catalysts during continuous operation (>160 h at 200 mA cm –2 ). Furthermore, this work provides a potential pathway for massively producing low-cost hydrogen using intermittent renewable energy sources.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Extreme-scale stochastic optimization and simulation via learning-enhanced decomposition and parallelization (Final Technical Report)

Stochastic optimization and simulation models ubiquitously arise in designing and operating complex service/engineering systems. They can be extreme in scale due to high-dimensional data and decisions, and can also involve decisions made sequentially in response to newly revealed data, both causing significant computational challenge. The objective of this research is to explore a unified framework that integrates machine learning with discrete optimization and risk-averse modeling, to improve the efficiency of decomposition paradigms for stochastic optimization and simulations at extreme scale. The models we consider represent a broad class of complex decision-making problems, where 0-1 or continuous decisions are made before and/or after knowing multiple sources of uncertainties that could be correlated. We will employ machine learning methods to dynamically decide and prioritize computational procedures, including cut generation, branching, and bounding of the optimal objective. Furthermore, the research will shed new lights on the traditional decomposition algorithms for extreme-scale computing. Deliverables of the research include new modeling and computational methods for advancing the state-of-the-art research in optimization and simulation, bringing many relevant risk-averse, data-driven optimization problems in practice within the range of tractability. Examples include distributed computing server scheduling and sensor deployment for monitoring critical infrastructures. Success in this effort will enable progress in solving multiple extreme-scale problems in the complex system design and operations arising from DoE missions in energy, environment, and national security.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

GPS-supported smartphone app-based integrated travel diary and time-use data collection: challenges and lessons learned

Travel behaviour and time-use data are two vital data sources for travel demand modelling. Travel behaviour is traditionally collected through household travel surveys, enhanced by using GPS-supported smartphone apps for passive location data collection. However, recruiting individuals willing to install these apps with sustained motivation to continue participation has been a critical challenge. This paper shares insights from a travel and time-use data collection procedure in Chicago and Sydney using the Fourstep app. Social media platforms were utilised as a solution to recruit participants in Chicago, where an international market research company failed to accomplish the task. This paper also discusses the challenges we faced and suggests ways to overcome them, offering valuable guidance to researchers in recruiting participants for smartphone application-based data collection. It also offers an analysis of travel, time-use, and travel-based multitasking behaviours based on the data collected from the Chicago and Sydney samples.

GPS-supported smartphone apps↗

DOE OSTI2024

Economically Viable Intermediate to Long Duration Hydrogen Energy Storage Solutions for Fossil Fueled Assets

This report was prepared as an account of work sponsored by the Office of Fossil Energy and Carbon Management of U.S. Department of Energy under Funding Opportunity Announcement Number DE-FOA-0002332 “Energy Storage for Fossil Power Generation”. The work aimed to explore and advance an innovative hydrogen energy storage system – the synergistically integrated hydrogen energy storage system (SIHES) – that has the following characteristics: • Compatible with existing or new coal and gas fuel electricity generation units, • best suited for intermediate to long duration energy storage, from 12 hours to weeks even months, and • capable of storing energy at the utility scale – hundreds of MWh to GWh energy storage with power output level in tens to hundreds of MW. Preliminary front-end engineering design (Pre-FEED) studies was carried out to develop and refine a site-specific SIHES as peaking power generation units (so named as HyPeaker) as the first market entry point, to demonstrate both the technical feasibility and the economic viability to integrate the HyPeaker “within the fence” of a fossil power plant. This specific site was TVA’s Johnsonville Combustion Turbine Plant. The HyPeaker was designed and engineered to integrate with a 60MW aeroderivative gas turbine unit already available at TVA’s Johnsonville site. This site-specific HyPeaker consists of an alkaline electrolyzer to produce hydrogen from CO 2 free electricity sources, an innovative low-cost high-pressure hydrogen storage system (Big-Ton) and the aero gas turbine to generate electricity using blend of hydrogen and natural gas. A holistic system level technoeconomic analysis tool specific to HyPeaker was developed to optimize the engineering design of the Johnsonville site-specific HyPeaker for cost and performance. The optimal design and specification of the Johnsonville site-specific HyPeaker are the following: • Alkaline electrolyzer: 3MW • Big-Ton storage vessel: 11,000kg H 2 at 3000psi. • 4-stage diaphragm hydrogen compressor: 55kg-H 2 /hr from 150psi to 3000psi. The HyPeaker is designed to provide sufficient hydrogen for 90% continuous operation of the HyPeaker. All major components have design life of 30 years. The capex of HyPeaker is estimated at $\$$7.1M. This included $\$$1.5M for the electrolyzer, $\$$5.6M for the storage vessel and compressor. The cost of aero gas turbine was included as it is already available at the site. Key findings are: • HyPeaker can be designed, manufactured, installed and integrated with the fossil power plants, with sub-systems and components commercially available on the market today, even when it is scaled up to an order of magnitude larger than the one at the Johnsonville site. HyPeaker is a technologically viable solution to cover a wide range of energy storage duration needs, from daily peaking operation to seasonal shifting for fossil fueled assets. • The cost advantage of SCCV based Big-Ton H 2 storage vessel made it possible to “oversize” the H 2 storage subsystem to achieve overall system level cost optimization. The benefits are two-fold. First, it allows to significantly reduce the capacity and cost of electrolyzer by spreading H 2 production over a much longer period of time when the fuel cost for electricity production is low. Second, it allows to balance the hydrogen production and usage shift over weeks to months to meet the peak demands. As such, the capital cost of HyPeaker system using the Big-Ton was less than half of the cost of a system with today’s steel tube based H 2 storage system. The HyPeaker has even better cost advantage Li-ion battery based energy storage system. The estimated capital cost of Li-Ion battery system would be at $\$$38M, under the same projected 20-year electricity generation profile of the Johnsonville site. This is over 5 times more expensive than the HyPeaker system. • Since industry scale energy storage systems do not have 100% energy conversion and storage efficiency, energy storage systems using fossil fuel generated electricity would increase the CO 2 emission. This is particularly the case for HyPeaker due to its low round trip efficiency. Therefore, a more sensible solution would be to the excessive or curtailed electricity from CO 2 emission free sources such as solar farms, wind farms or nuclear power plants, to produce hydrogen, and integrate them with the HyPeaker. Electricity from TVA’s nuclear power plants was used for the Johnsonville HyPeaker. • The economic viability of HyPeaker is expected to be further improved when global supply chains are taken into consideration. For the same Johnsonville site specific HyPeaker, the capex would be reduced to ~$\$$3.6M from ~$\$$7.1M, and the added LCOE is reduced to ~$\$$85/MWh. With the bipartisan Infrastructure Investment and Jobs Act, the cost of domestically produced HyPeaker sub-systems would be at the level of today’s global suppliers. Since the peaking units generally operate at peak usage period, thereby demanding higher price, the projected $\$$85/MWh LCOE would be within the realm of financial viability for utility operators.

08 HYDROGEN↗

DOE OSTI2021

Combustion Performance and Emissions Optimization through Integration of Miniaturized High Temperature Multi Process Monitoring System

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of coal-fired utility boilers in this project but can be applied to many other industries and applications as well. The new sensor design, leveraging the existing electrochemical noise-based monitoring system, is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data can be transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, five mMPMS were installed at a full-scale pulverized coal-fired plant, Basin Electric Power Cooperative’s Leland Olds Unit 1. The systems were demonstrated over a 6-week period during typical operation. Sensor measurements of deposit thickness were validated during the demonstration and subsequently leveraged to determine sensor-based boiler cleaning strategies. These strategies have the benefit of reduced thermal stresses on boiler tubes from over-cleaning and improved boiler water management. At the end of the project, continued development of the sensor technology was carried out at PacifiCorp’s Hunter Station. REI leveraged the permanent installation of the mMPMS in Unit 3 made possible by DOE funding on a separate program. The work at Hunter Plant focused on application of machine learning and artificial intelligence-based models for integration of sensor signals into control and optimization of Hunter Unit 3 processes.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

DOE OSTI2022

Combustion Performance and Emissions Optimization Through Integration of a Miniaturized High-Temperature Multi Process Monitoring System

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

DOE OSTI2020

Combustion Performance and Emissions Optimization Through Integration of a Miniaturized High-Temperature Multi Process Monitoring System

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of coal-fired utility boilers in this project but can be applied to many other industries and applications as well. This project leveraged the existing electrochemical noise-based monitoring system and the new sensor design is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data is transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, five mMPMS were installed at a full-scale pulverized coal-fired plant, Basin Electric Power Cooperative’s Leland Olds Unit 1. The systems were demonstrated over a 6-week period during typical operation. Sensor measurements of deposit thickness were validated during the demonstration and subsequently leveraged to determine sensor-based boiler cleaning strategies. These strategies have the benefit of reduced thermal stresses on boiler tubes from over-cleaning and improved boiler water management. At the end of the project, continued development of the sensor technology was carried out at PacifiCorp’s Hunter Station. REI leveraged the permanent installation of the mMPMS in Unit 3 made possible by DOE funding on a separate program. The work at Hunter Plant focused on application of machine learning and artificial intelligence-based models for integration of sensor signals into control and optimization of Hunter Unit 3 processes.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗

DOE OSTI2024

Combustion Performance and Emissions Optimization Through Integration of a Miniaturized High-Temperature Multi Process Monitoring System

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution of wall conditions in utility boilers. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of a coal-fired utility boiler in this project but can be applied to many other industries and applications as well. The new sensor design, leveraging the existing electrochemical noise-based monitoring system, is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data can be transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, five mMPMS were installed at a full-scale pulverized coal-fired plant, Basin Electric Power Cooperative’s Leland Olds Unit 1. The systems were demonstrated over a 6-week period during typical operation. Sensor measurements of deposit thickness were validated during the demonstration and subsequently leveraged to determine sensor-based boiler cleaning strategies. These strategies have the benefit of reduced thermal stresses on boiler tubes from over-cleaning and improved boiler water management. At the end of the project, continued development of the sensor technology was carried out at PacifiCorp’s Hunter Station. REI leveraged the permanent installation of the mMPMS in Unit 3 made possible by DOE funding on a separate program. The work at Hunter Plant focused on application of machine learning and artificial intelligence-based models for integration of sensor signals into control and optimization of Hunter Unit 3 processes.

42 ENGINEERING↗

DOE OSTI2022

Metal–Organic Framework Integrating Ionic Framework and Bimetallic Coupling Effect for Highly Efficient Oxygen Evolution Reaction

Metal–organic frameworks (MOFs) are recognized as promising electrocatalysts for the oxygen evolution reaction (OER) because of their permanent porosity and rich architectural diversity; however, ionic MOFs enabling fast ions exchange during OER are rarely explored. Here, an ionic MOF (Ni-btz) constructed with an azolate ligand is selected, and continuous 3D bimetallic MOF (NiFe-btz) films deriving from high-degree intergrowth of microsized MOFs particles are fabricated. The as-prepared NiFe-btz/NF-OH electrode exhibits excellent OER performance with a low overpotential of 239 mV at 10 mA cm –2 under alkaline condition. The OER charge transfer process and bimetallic coupling effect in ionic NiFe-btz are probed by density functional theory calculations and confirmed via X-ray photoelectron spectroscopy and in situ Raman measurements. The partial density of states of NiFe-btz indicates that the main contribution for electron density around the Fermi level is from Cl ions clarifying the profitable impact of ionic MOF framework. This work systematically demonstrates the relationship of electronic structure and OER activity in ionic, bimetallic MOFs and expands the scope of 3D MOF films for efficient OER.

36 MATERIALS SCIENCE↗